CN111224576A - High and low voltage composite pulse power supply based on parallel connection of Boost and Buck - Google Patents

High and low voltage composite pulse power supply based on parallel connection of Boost and Buck Download PDF

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Publication number
CN111224576A
CN111224576A CN202010072988.8A CN202010072988A CN111224576A CN 111224576 A CN111224576 A CN 111224576A CN 202010072988 A CN202010072988 A CN 202010072988A CN 111224576 A CN111224576 A CN 111224576A
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circuit
voltage
switch tube
inductor
power supply
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杨飞
覃徳凡
吴鹏程
史顺飞
汪志鹏
邵佳钰
李宏良
王一娉
李磊
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Nanjing University of Science and Technology
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Nanjing University of Science and Technology
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    • H—ELECTRICITY
    • H03—ELECTRONIC CIRCUITRY
    • H03K—PULSE TECHNIQUE
    • H03K3/00—Circuits for generating electric pulses; Monostable, bistable or multistable circuits
    • H03K3/02—Generators characterised by the type of circuit or by the means used for producing pulses
    • H03K3/53—Generators characterised by the type of circuit or by the means used for producing pulses by the use of an energy-accumulating element discharged through the load by a switching device controlled by an external signal and not incorporating positive feedback

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Abstract

The invention discloses a high-low voltage composite pulse power supply based on Boost and Buck parallel connection, which comprises a direct current input power supply, a high-voltage breakdown circuit, a low-voltage discharge circuit, a gap current detection circuit, a gap voltage detection circuit, a drive circuit and an FPGA controller, wherein the high-voltage breakdown circuit and the low-voltage discharge circuit form a pulse power supply main circuit, a composite circuit topology that a Boost circuit is connected with a plurality of synchronous rectification Buck circuits which are connected in parallel in a staggered mode is adopted, and the low-voltage discharge circuit is controlled in a current closed loop mode; the high-voltage breakdown loop adopts voltage closed-loop control; and the flexible switching between the high-voltage breakdown circuit and the low-voltage discharge circuit is completed through the judgment of the gap voltage. The invention improves the energy utilization rate of the pulse power supply, reduces output current ripples, and realizes that the breakdown high voltage can be adjusted and the discharge current waveform can be controlled.

Description

High-low voltage composite pulse power supply based on Boost and Buck parallel connection
Technical Field
The invention relates to an electric spark forming processing pulse power supply, in particular to a high-low voltage composite pulse power supply based on Boost and Buck parallel connection.
Background
The electric spark forming processing is commonly used for processing a cavity in the production of a die, and the electrolyte adopts spark oil which has high insulativity and needs to apply high voltage for gap breakdown. Along with the increase of the processing depth, the electric spark forming machine tool has poor chip removal, so that the discharge condition is easy to deteriorate, and the abnormal discharge phenomenon becomes more. The magnitude of the distance between the tool electrode and the workpiece electrode is regulated by the voltage across the gap, subject to the current average voltage method of servo tracking. At present, a resistance type pulse power supply is mainly adopted as a pulse power supply for electric spark forming machining, and high voltage for gap breakdown is provided through a transformer and cannot be flexibly adjusted; the discharge energy can be controlled only by adjusting the size of the discharge resistor and the switching frequency, and the defects of low electric energy utilization rate, poor current waveform controllability and the like exist.
Disclosure of Invention
The invention aims to provide a high-low voltage composite pulse power supply based on Boost and Buck parallel connection.
The technical solution for realizing the purpose of the invention is as follows: a high-low voltage composite pulse power supply based on Boost and Buck parallel connection comprises a direct current input power supply, a high-voltage breakdown circuit, a low-voltage discharge circuit, a gap current detection circuit, a gap voltage detection circuit, a drive circuit and an FPGA controller, wherein the high-voltage breakdown circuit and the low-voltage discharge circuit form a pulse power supply main circuit, and a composite circuit topology that a Boost circuit is connected in parallel with a plurality of synchronous rectification Buck circuits which are alternately connected in parallel is adopted; the direct-current power supply is used for supplying power to the high-voltage breakdown loop and the low-voltage discharge loop; the high-voltage breakdown loop is used for providing high voltage required by gap breakdown; the low-voltage discharge loop is used for providing discharge energy; the voltage detection circuit and the current detection circuit are used for sampling the gap voltage and the gap discharge current; the FPGA controller generates a plurality of paths of PWM signals according to the voltage and current sampling signals; the driving circuit is used for filtering and amplifying the PWM signal and controlling the on and off of the switching tubes in the high-voltage breakdown circuit and the low-voltage discharge circuit.
The pulse power supply main circuit comprises a first switch tube, a second switch tube, a third switch tube, a fourth switch tube, a fifth switch tube, a sixth switch tube, a seventh switch tube, an eighth switch tube, a ninth switch tube, a deionization switch tube, a low-voltage discharge circuit switch tube, a high-voltage breakdown circuit switch tube, a first inductor, a second inductor, a third inductor, a fourth inductor, a fifth inductor, a first capacitor, a second capacitor, a first output diode, a second output diode, a third output diode, a fourth output diode, a fifth diode and a feedback diode, wherein the first switch tube, the second switch tube, the first output diode and the first inductor form a first path of synchronous rectification Buck circuit; the third switching tube, the fourth switching tube, the second output diode and the second inductor form a second path of synchronous rectification Buck circuit; a third synchronous rectification Buck circuit is formed by a fifth switching tube, a sixth switching tube, a third output diode and a third inductor; a seventh switching tube, an eighth switching tube, a fourth output diode and a fourth inductor form a fourth synchronous rectification Buck circuit; a ninth switching tube, a fifth diode, a fifth inductor and a second capacitor form a Boost circuit; one end of an upper tube of the four-path synchronous rectification Buck circuit is connected to the positive electrode of the input direct-current power supply, and the other end of the upper tube is respectively connected with the first inductor, the second inductor, the third inductor and the fourth inductor in series; one end of a lower tube of the four-path synchronous rectification Buck circuit is respectively connected to a series point between the first inductor, the second inductor, the third inductor, the fourth inductor and the upper tube, and the other end of the lower tube is connected with the negative pole of the input direct-current power supply, namely the lower tube is grounded; one end of a first inductor, a second inductor, a third inductor and a fourth inductor in the four-path synchronous rectification Buck circuit is connected to a common point of an upper tube and a lower tube, and the other end of the first inductor, the second inductor, the third inductor and the fourth inductor is connected with the anode of an output diode; the cathodes of output diodes in the four paths of synchronous rectification Buck circuits are connected together and connected to one end of a low-voltage discharge circuit switching tube, and the other end of the low-voltage discharge circuit switching tube is connected to the anode of the gap; the Boost circuit is connected with the four-way synchronous rectification Buck circuit in parallel, namely one end of the fifth inductor is connected with the anode of the input direct-current power supply, and the other end of the fifth inductor is connected with the anode of the fifth diode; the negative electrode of the fifth diode is connected with a high-voltage breakdown circuit switching tube; one end of the ninth switching tube is connected with a common point between the fifth inductor and the fifth diode, and the other end of the ninth switching tube is connected with the negative pole of the input direct-current power supply, namely the ninth switching tube is grounded; one end of the second capacitor is connected to a common point between the fifth diode and the switching tube of the high-voltage breakdown circuit, and the other end of the second capacitor is connected to the negative pole of the input direct-current power supply, namely the negative pole is grounded; the first capacitor is connected with the direct current input power supply in parallel; the cathode of the feedback diode is connected with the anode of the direct current power supply, and the anode of the feedback diode is connected with the cathode of the first output diode; the two ends of the gap are also connected with a deionization switch tube in parallel; the other end of the gap is connected to the negative pole of the input direct current power supply.
The first switch tube, the second switch tube, the third switch tube, the fourth switch tube, the fifth switch tube, the sixth switch tube, the seventh switch tube, the eighth switch tube, the ninth switch tube, the deionization switch tube, the low-voltage discharge circuit switch tube and the high-voltage breakdown circuit switch tube adopt metal-oxide semiconductor field effect transistors.
The first inductor, the second inductor, the third inductor, the fourth inductor and the fifth inductor are independent inductors, and the magnetic core is made of a sintered magnetic metal oxide made of an iron oxide mixture and made of PC 40.
The first output diode, the second output diode, the third output diode, the fourth output diode, the fifth diode and the feedback diode are Schottky diodes.
The gap voltage detection circuit selects a resistance voltage division circuit.
The gap current detection circuit selects a current hall sensor.
The FPGA controller selects an AX301 series development board.
The driving circuit adopts a driving chip with isolated high-side and low-side dual-output.
The processing control method of the power supply comprises the following steps:
the method comprises the following steps: in the breakdown delay stage, the FPGA controller controls the switching tube of the low-voltage discharge circuit to be switched off, the switching tube of the high-voltage breakdown circuit to be switched on, and the deionization switch tube to be switched off; the first switching tube, the second switching tube, the third switching tube, the fourth switching tube, the fifth switching tube, the sixth switching tube, the seventh switching tube and the eighth switching tube are turned off; at the moment, a Boost circuit consisting of a ninth switching tube, a fifth diode, a fifth inductor and a second capacitor provides high voltage for the gap, and the FPGA controller outputs a PWM signal to control the duty ratio of the ninth switching tube according to the processing environment and an error signal of gap sampling voltage and a voltage set value, so that the high voltage applied to two ends of the gap is adjusted, and a stable discharge channel is formed;
step two: when the gap is broken down, the gap voltage is reduced to a maintaining voltage from the original open-circuit voltage, the FPGA controller outputs a plurality of paths of PWM signals to control the conduction of the low-voltage discharge switching tube, the switching tube of the high-voltage breakdown circuit is switched off, and the switching from the high-voltage breakdown circuit to the low-voltage discharge circuit is completed;
step three: after the high-voltage breakdown circuit and the low-voltage discharge circuit are switched, the low-voltage discharge circuit starts to provide discharge energy required by machining for the gap, the FPGA controller outputs a plurality of paths of PWM signals according to error signals of gap sampling current and current reference values to control four paths of synchronous rectification Buck circuits to work in a staggered mode, the phase difference of the PWM signals between two adjacent paths is equal to one fourth of the switching period, a certain dead time is reserved for driving signals between upper and lower tubes of the single-path synchronous rectification Buck circuit, and then the continuous discharge machining stage is started;
step four: when the discharge duration reaches a set value, the FPGA controller outputs a plurality of paths of PWM signals to control the switching tube of the low-voltage discharge circuit to be switched off, the switching tube of the high-voltage breakdown circuit is switched off, the deionization switching tube is switched off, the first switching tube, the third switching tube, the fifth switching tube and the seventh switching tube are switched off, the second switching tube, the fourth switching tube, the sixth switching tube and the eighth switching tube are switched on, the ninth switching tube is switched off, energy in the first inductor, the second inductor, the third inductor, the fourth inductor and the fifth inductor is fed back to the input direct-current power supply through the feedback diodes, and at the moment, the discharge tailing stage is started.
Step five: after the gap current is reduced to zero, the FPGA controller outputs a plurality of paths of PWM signals to control the deionization switch tube to be switched on, other switch tubes are switched off, the voltage at two ends of the gap is reduced to zero, and the deionization device enters a deionization stage and prepares for discharging in the next period;
step six: and repeating the five steps to realize the cycle of the processing period.
Compared with the prior art, the invention has the following remarkable advantages: 1) the electric spark machining stability and machining efficiency are improved by adopting a power electronic high-low voltage composite structure; 2) the low-voltage discharge loop adopts a topological structure in staggered parallel connection, so that power expansion is facilitated, switching frequency is equivalently improved, output current ripples are effectively reduced, and the volume of a magnetic element is reduced; 3) the high-voltage breakdown circuit adopts voltage closed-loop control to realize continuous adjustable output high voltage, and the low-voltage discharge circuit adopts current closed-loop control to realize flexible and variable output current waveform according to reference current, so that discharge energy is controllable, and the requirements of different processing modes are met; 4) the switching between the high-voltage breakdown circuit and the low-voltage discharge circuit is carried out by adopting gap voltage judgment, so that the flexibility and the reliability of the switching of the high-voltage circuit and the low-voltage circuit are improved.
Drawings
Fig. 1 is a block diagram of a high-low voltage composite pulse power supply system based on Boost and Buck parallel connection.
Fig. 2 is a schematic topology diagram of a high-low voltage composite pulse power supply based on the parallel connection of Boost and Buck.
Fig. 3 is a schematic diagram of a single-path current closed-loop control adopted by the low-voltage discharge circuit in the invention.
Fig. 4 is a flowchart of the switching control procedure of the high-low voltage circuit according to the present invention.
Fig. 5 is a schematic diagram of a typical discharge waveform of a high-low voltage composite type pulse power supply topology based on the parallel connection of Boost and Buck.
Detailed Description
The invention is described in further detail below with reference to the accompanying drawings.
As shown in fig. 1, the high-low voltage composite pulse power supply based on the parallel connection of the Boost circuit and the Buck circuit comprises a direct current input power supply, a high-voltage breakdown circuit, a low-voltage discharge circuit, a gap current detection circuit, a gap voltage detection circuit, a drive circuit and an FPGA controller, wherein the high-voltage breakdown circuit and the low-voltage discharge circuit form a pulse power supply main circuit, and a composite circuit topology in which the Boost circuit is connected in parallel with a plurality of synchronous rectification Buck circuits in a staggered parallel connection mode is adopted; the direct-current power supply is used for supplying power to the high-voltage breakdown loop and the low-voltage discharge loop; the high-voltage breakdown loop is used for providing high voltage required by gap breakdown; the low-voltage discharge loop is used for providing discharge energy; the voltage detection circuit and the current detection circuit are used for sampling the gap voltage and the gap discharge current; the FPGA controller generates a plurality of paths of PWM signals according to the voltage and current sampling signals; the driving circuit is used for filtering and amplifying the PWM signal and controlling the on and off of the switching tubes in the high-voltage breakdown circuit and the low-voltage discharge circuit.
As shown in fig. 2, the main circuit of the pulse power supply includes a first switch tube Q1A second switch tube Q2And a third switching tube Q3And a fourth switching tube Q4The fifth switch tube Q5And a sixth switching tube Q6Seventh switch tube Q7The eighth switch tube Q8And a ninth switching tube Q9Deionization switch tube QoffSwitching tube Q of low-voltage discharge circuitLSwitching tube Q of high-voltage breakdown circuitHA first inductor L1A second inductor L2A third inductor L3A fourth inductor L4A fifth inductor L5A first capacitor CinA second capacitor CoA first output diode D1A second output diode D2A third output diode D3A fourth output diode D4A fifth diode D5And a feedback diode DbackWherein the first switch tube Q1A second switch tube Q2A first output diode D1A first inductor L1Forming a first path of synchronous rectification Buck circuit; third switch tube Q3And a fourth switching tube Q4A second output diode D2A second inductor L2Forming a second path of synchronous rectification Buck circuit; fifth switch tube Q5And a sixth switching tube Q6A third output diode D3A third inductor L3Forming a third synchronous rectification Buck circuit; seventh switch tube Q7The eighth switch tube Q8A fourth output diode D4A fourth inductor L4Forming a fourth path of synchronous rectification Buck circuit; ninth switch tube Q9A fifth diode D5A fifth inductor L5And a second capacitor CoForming a Boost circuit; one end of an upper tube of the four-way synchronous rectification Buck circuit is connected to the positive electrode of the input direct-current power supply, and the other end of the upper tube is respectively connected with the first inductor L1A second inductor L2A third inductor L3A fourth inductor L4Are connected in series; one end of a lower tube of the four-way synchronous rectification Buck circuit is respectively connected to a first inductor L1A second inductor L2A third inductor L3A fourth inductor L4The other end of the series point between the upper tube and the lower tube is connected with the negative pole of the input direct current power supply, namely the input direct current power supply is grounded; first inductor L in four-way synchronous rectification Buck circuit1A second inductor L2A third inductor L3A fourth inductor L4One end of the output diode is connected to the common point of the upper tube and the lower tube, and the other end of the output diode is connected with the anode of the output diode; the cathodes of output diodes in the four-way synchronous rectification Buck circuit are connected together and connected to a switching tube Q of the low-voltage discharge circuitLOne end of (1), a low-voltage discharge circuit switching tube QLThe other end of the first end is connected to the positive pole of the gap; the Boost circuit is connected with the four-way synchronous rectification Buck circuit in parallel, namely a fifth inductor L5One end of the first diode is connected with the anode of the input direct current power supply, and the other end of the first diode is connected with the fifth diode D5The positive electrode of (1); fifth diode D5Negative electrode of the switching tube Q is connected with a high-voltage breakdown circuitH(ii) a Ninth switch tube Q9Is connected with a fifth inductor L5And a fifth diode D5The other end of the common point is connected with the cathode of the input direct current power supply, namely the common point is grounded; second capacitor CoIs connected to a fifth diode D5Switching tube Q connected with high-voltage breakdown circuitHThe other end of the common point is connected with the cathode of the input direct current power supply, namely the common point is grounded; a first capacitor CinIs connected with a direct current input power supply in parallel; feedback diode DbackIs connected with the anode of the DC power supply, and the anode of the DC power supply is connected with a first output diode D1Are connected together; the two ends of the gap are also connected with a deionization switch tube Q in paralleloff(ii) a The other end of the gap is connected to the negative pole of the input direct current power supply.
Further, the first switch tube Q1A second switch tube Q2And a third switching tube Q3And a fourth switching tube Q4The fifth switch tube Q5And a sixth switching tube Q6Seventh switch tube Q7The eighth switch tube Q8And a ninth switching tube Q9Deionization switch tube QoffSwitching tube Q of low-voltage discharge circuitLSwitching tube Q of high-voltage breakdown circuitHA metal-oxide semiconductor field effect transistor is used. First switch tube Q in high-low voltage composite pulse power supply1A second switch tube Q2And a third switching tube Q3And a fourth switching tube Q4The fifth switch tube Q5And a sixth switching tube Q6Seventh switch tube Q7The eighth switch tube Q8An N-channel MOSFET from FAIRCHILD, model FCP36N60N, may be selected. Ninth switch tube Q9Deionization switch tube QoffSwitching tube Q of low-voltage discharge circuitLSwitching tube Q of high-voltage breakdown circuitHAn N-channel MOSFET with the model number of IPP60R074C6 and manufactured by Infineon company can be selected, the on-resistance is small, and the switching loss and the on-loss are low.
Further, the first inductor L1A second inductor L2A third inductor L3A fourth inductor L4A fifth inductor L5Selecting independent inductor and magnetic core of different oxygenThe material of the sintered magnetic metal oxide composed of the iron-oxide mixture can be selected from PC 40.
Further, the first output diode D1A second output diode D2A third output diode D3A fourth output diode D4A fifth diode D5And a feedback diode DbackSchottky diodes are used. The first output diode D1A second output diode D2A third output diode D3A fourth output diode D4And a feedback diode DbackA Schottky diode of the type MBR40250TG from ONSemiconductor may be used, and the peak voltage V may be repeated in reverse directionRRMUp to 250V, average forward current IF(AV)Is 40A; fifth diode D5ON Semiconductor corporation, model FFP30S60S schottky diode with peak reverse voltage VRRMUp to 600V, average forward current IF(AV)At 30A, the switching speed is less than 40 ns.
In order to accurately sample the gap current and the gap voltage in real time, a proper current and voltage detection circuit is also needed. The gap current detection circuit selects a current Hall sensor, can select a current detection chip with the model number of ACS733KLATR-65AB-T, and is provided with good linearity and high detection precision. The gap voltage detection circuit adopts a traditional resistance voltage division circuit, and is simple and reliable.
Further, the digital controller selects an FPGA controller with wider industrial control application, and comprehensively considers resources to select a development module AX301 of ALINX company; the corresponding sampling module is an ALINX9226 module matched with an FPGA development board of an AX4010 model by ALINX company.
Furthermore, the driving circuit adopts a high-side and low-side dual-output driving chip with isolation, a gate driving chip with a model of UCC21220 of Texas instruments can be selected, high-side and low-side dual-output driving is achieved, isolation is provided, and interference between a main circuit and a control circuit is reduced.
In conclusion, the high-low voltage composite type pulse power supply topology based on the parallel connection of the Boost and the Buck adopts the high-low voltage composite type topology, so that the stability and the processing efficiency of the electric spark processing are improved; the multi-path staggered parallel topology structure is convenient for power expansion, can equivalently improve the switching frequency, and effectively reduces output current ripples by staggered superposition of multi-path inductive current; the feedback diode can feed back the inductive energy to the input direct current power supply, and the energy utilization rate is improved.
FIG. 3 is a schematic diagram of a single-path current closed-loop control of a four-path interleaved synchronous rectification Buck circuit. By sampling the gap current i in real timedAnd a reference current irefComparing the error values, and passing the compared error values through a compensation circuit AvGenerating a compensation signal veAnd finally, obtaining a final PWM control signal through a PWM modulator. In order to minimize the gap current ripple, sawtooth waves v of PWM modulators in two adjacent synchronous rectification Buck circuitssawThe phases differ by 90. The voltage closed loop uses conventional PI control to obtain the final PWM control signal.
Fig. 4 is a flowchart of the switching control procedure of the high-low voltage circuit according to the present invention. In a complete processing period, the FPGA controller firstly controls the switching tube of the high-voltage breakdown circuit to be conducted, the switching tube of the low-voltage discharge loop is switched off, and at the moment, the high-voltage circuit starts to work to apply high voltage to a gap for gap breakdown; by sampling the gap voltage vdPerforming voltage comparison if the gap voltage is equal to the sustain voltage vdisThe controller FPGA controls the switching tube of the high-voltage breakdown circuit to be switched off, the switching tube of the low-voltage discharge loop is switched on, and at the moment, the low-voltage discharge loop starts to work to provide discharge energy for the gap. And after one discharge period is finished, switching to the next discharge period until the complete discharge process is finished.
Fig. 5 is a typical gap voltage and current waveform diagram for a complete machining cycle of spark forming, which is divided into three phases: breakdown delay period tdelayAnd a discharge stage tonAnd a deionization phase toff. In the breakdown delay stage, the gap is in an insulation state, the gap current is 0, and the gap voltage is equal to the open-circuit voltage vopen(ii) a After the gap is broken down, the discharge stage is entered,the gap voltage is reduced from the original open circuit voltage to the maintaining voltage vdisAt this time, the waveform of the discharge current follows the reference current irefA change in (c); after the discharge is finished, the deionization stage is started, and the gap voltage and the gap current are both reduced to 0. The processing control method of the high-low voltage composite pulse power supply based on the Boost and the Buck in parallel connection comprises the following specific implementation processes:
the method comprises the following steps: in the breakdown delay stage, the FPGA controller controls the switching tube of the low-voltage discharge circuit to be switched off, the switching tube of the high-voltage breakdown circuit to be switched on, and the deionization switch tube to be switched off; the first switching tube, the second switching tube, the third switching tube, the fourth switching tube, the fifth switching tube, the sixth switching tube, the seventh switching tube and the eighth switching tube are turned off; at this time, a Boost circuit composed of the ninth switching tube, the fifth diode, the fifth inductor and the second capacitor provides high voltage for the gap. Under different processing environments, the FPGA controller outputs a PWM signal to control the duty ratio of the ninth switching tube according to an error signal of the gap sampling voltage and a voltage set value, so that the high voltage applied to two ends of the gap is adjusted, and a stable discharge channel is formed;
step two: when the gap is broken down, the gap discharge stage is started, the gap voltage is reduced to a maintaining voltage from the original open-circuit voltage, the FPGA controller outputs a plurality of paths of PWM signals to control the conduction of the low-voltage discharge switching tube, the switching tube of the high-voltage breakdown circuit is switched off, and the switching from the high-voltage breakdown circuit to the low-voltage discharge circuit is completed;
step three: after the switching between the high-voltage breakdown circuit and the low-voltage discharge circuit is completed, the low-voltage discharge circuit starts to provide discharge energy required by machining for the gap. The FPGA controller outputs a plurality of paths of PWM signals according to error signals of the gap sampling current and the current reference value to control four paths of synchronous rectification Buck circuits to work in a staggered mode, the phase difference of the PWM signals between two adjacent paths is equal to one fourth of the switching period, and the ripple of the total output current reaches the minimum. In order to prevent the input short circuit of the low-voltage discharge circuit caused by the rising time and the falling time of the switching tube, a certain dead time is left for the driving signals between the upper tube and the lower tube of the single-path synchronous rectification Buck circuit. At the moment, entering a continuous discharge machining stage, and setting different reference currents to obtain any discharge current waveform so as to meet the requirements of different machining modes of rough machining, medium machining and fine machining;
step four: when the discharge duration time reaches a set value, the FPGA controller outputs a plurality of paths of PWM signals to control the switching tube of the low-voltage discharge circuit to be switched off, the switching tube of the high-voltage breakdown circuit to be switched off, the deionization switching tube to be switched off, the first switching tube, the third switching tube, the fifth switching tube and the seventh switching tube to be switched off, the second switching tube, the fourth switching tube, the sixth switching tube and the eighth switching tube to be switched on, and the ninth switching tube to be switched off. Inductor L1、L2、L3And L4The energy in the power supply is fed back to the input direct current power supply through the feedback diode, so that the energy utilization rate is improved. At this point the discharge tail phase is entered.
Step five: after the gap current is reduced to zero, the FPGA controller outputs a plurality of paths of PWM signals to control the deionization switch tube to be switched on, and other switch tubes are switched off, so that the voltage at two ends of the gap is reduced to zero, and the deionization circuit enters a deionization stage and prepares for discharging in the next period.
Step six: and repeating the five steps to realize the cycle of the processing period.
In conclusion, in a complete machining process, aiming at the load characteristic of electric spark machining, the voltage is sampled according to the gap, and the FPGA controller controls the high-voltage breakdown circuit and the low-voltage discharge circuit to be freely switched; in the breakdown delay stage, according to different processing modes and processing requirements, the high voltage applied to the two ends of the gap can be flexibly adjusted through voltage closed-loop control. In the discharge machining stage, the synchronous rectification Buck circuits which are connected in parallel in a multi-path staggered mode work cooperatively, so that the working frequency of the circuit is equivalently improved, and output current ripples are reduced. By adopting current closed-loop control, any discharge current waveform can be realized by setting reference current, so that the discharge energy can be controlled.

Claims (10)

1.一种基于Boost和Buck并联的高低压复合型脉冲电源，其特征在于，包括直流输入电源、高压击穿回路、低压放电回路、间隙电流检测电路、间隙电压检测电路、驱动电路、FPGA控制器，其中高压击穿回路、低压放电回路构成脉冲电源主电路，采用Boost电路与多路交错并联的同步整流Buck电路并联的复合型电路拓扑；直流电源用于给高压击穿回路和低压放电回路供电；高压击穿回路用于提供间隙击穿所需要的高压；低压放电回路用于提供放电能量；电压检测电路和电流检测电路用于对间隙电压和间隙放电电流进行采样；FPGA控制器根据电压和电流采样信号产生多路PWM信号；驱动电路用于对PWM信号进行滤波、放大，控制高压击穿回路和低压放电回路中开关管的导通和关断。1. a high and low voltage composite pulse power supply based on Boost and Buck in parallel, is characterized in that, comprises DC input power supply, high voltage breakdown circuit, low voltage discharge circuit, gap current detection circuit, gap voltage detection circuit, drive circuit, FPGA control Among them, the high-voltage breakdown circuit and the low-voltage discharge circuit constitute the main circuit of the pulse power supply, and a composite circuit topology in which the Boost circuit is connected in parallel with the synchronous rectification Buck circuit of multiple interleaved parallel circuits is adopted; the DC power supply is used for the high-voltage breakdown circuit and the low-voltage discharge circuit. Power supply; high-voltage breakdown circuit is used to provide the high voltage required for gap breakdown; low-voltage discharge circuit is used to provide discharge energy; voltage detection circuit and current detection circuit are used to sample the gap voltage and gap discharge current; FPGA controller according to the voltage and the current sampling signal to generate multiple PWM signals; the driving circuit is used to filter and amplify the PWM signals, and control the on and off of the switching tubes in the high-voltage breakdown circuit and the low-voltage discharge circuit. 2.根据权利要求1所述的基于Boost和Buck并联的高低压复合型脉冲电源，其特征在于，所述脉冲电源主电路包括第一开关管(Q1)、第二开关管(Q2)、第三开关管(Q3)、第四开关管(Q4)、第五开关管(Q5)、第六开关管(Q6)、第七开关管(Q7)、第八开关管(Q8)、第九开关管(Q9)、消电离开关管(Qoff)、低压放电电路切换管(QL)、高压击穿电路切换管(QH)、第一电感(L1)、第二电感(L2)、第三电感(L3)、第四电感(L4)、第五电感(L5)、第一电容(Cin)、第二电容(Co)、第一输出二极管(D1)、第二输出二极管(D2)、第三输出二极管(D3)、第四输出二极管(D4)、第五二极管(D5)和反馈二极管(Dback)，其中第一开关管(Q1)、第二开关管(Q2)、第一输出二极管(D1)、第一电感(L1)组成第一路同步整流Buck电路；第三开关管(Q3)、第四开关管(Q4)、第二输出二极管(D2)、第二电感(L2)组成第二路同步整流Buck电路；第五开关管(Q5)、第六开关管(Q6)、第三输出二极管(D3)、第三电感(L3)组成第三路同步整流Buck电路；第七开关管(Q7)、第八开关管(Q8)、第四输出二极管(D4)、第四电感(L4)组成第四路同步整流Buck电路；第九开关管(Q9)、第五二极管(D5)、第五电感(L5)和第二电容(Co)组成Boost电路；四路同步整流Buck电路的上管的一端连接到输入直流电源的正极，另一端分别与第一电感(L1)、第二电感(L2)、第三电感(L3)、第四电感(L4)串联；四路同步整流Buck电路的下管的一端分别连接到第一电感(L1)、第二电感(L2)、第三电感(L3)、第四电感(L4)与上管之间的串联点，另一端连接输入直流电源的负极，即为接地；四路同步整流Buck电路中第一电感(L1)、第二电感(L2)、第三电感(L3)、第四电感(L4)的一端连接到上管和下管的公共点，另一端连接输出二极管的正极；四路同步整流Buck电路中输出二极管的负极连接在一起接到低压放电电路切换管(QL)的一端，低压放电电路切换管(QL)的另一端接到间隙的正极；Boost电路和四路同步整流Buck电路并联，即第五电感(L5)的一端连接输入直流电源的正极，另一端连接第五二极管(D5)的正极；第五二极管(D5)的负极连接高压击穿电路切换管(QH)；第九开关管(Q9)的一端连接第五电感(L5)与第五二极管(D5)之间的公共点，另一端连接输入直流电源的负极，即为接地；第二电容(Co)的一端连接到第五二极管(D5)与高压击穿电路切换管(QH)之间的公共点，另一端连接输入直流电源的负极，即为接地；第一电容(Cin)与直流输入电源并联连接；反馈二极管(Dback)的负极与直流电源的正极连接在一起，其正极与第一输出二极管(D1)的负极连接在一起；在间隙的两端还并联着消电离开关管(Qoff)；间隙另一端连接到输入直流电源的负极。2. The high and low voltage composite pulse power supply based on Boost and Buck in parallel according to claim 1, wherein the main circuit of the pulse power supply comprises a first switch tube (Q 1 ), a second switch tube (Q 2 ) , the third switch tube (Q 3 ), the fourth switch tube (Q 4 ), the fifth switch tube (Q 5 ), the sixth switch tube (Q 6 ), the seventh switch tube (Q 7 ), the eighth switch tube (Q 8 ), the ninth switch tube (Q 9 ), the deionization switch tube (Q off ), the low-voltage discharge circuit switch tube (Q L ), the high-voltage breakdown circuit switch tube (Q H ), the first inductor (L 1 ) ), the second inductance (L 2 ), the third inductance (L 3 ), the fourth inductance (L 4 ), the fifth inductance (L 5 ), the first capacitance (C in ), the second capacitance (C o ), A first output diode (D 1 ), a second output diode (D 2 ), a third output diode (D 3 ), a fourth output diode (D 4 ), a fifth diode (D 5 ), and a feedback diode (D back ), wherein the first switch tube (Q 1 ), the second switch tube (Q 2 ), the first output diode (D 1 ), and the first inductor (L 1 ) form the first synchronous rectification Buck circuit; the third switch tube (Q 3 ), the fourth switch tube (Q 4 ), the second output diode (D 2 ), and the second inductor (L 2 ) form the second synchronous rectification Buck circuit; the fifth switch tube (Q 5 ), the first Six switch tubes (Q 6 ), third output diodes (D 3 ), and third inductors (L 3 ) form a third synchronous rectification Buck circuit; the seventh switch tube (Q 7 ) and the eighth switch tube (Q 8 ) , the fourth output diode (D 4 ), and the fourth inductor (L 4 ) form the fourth synchronous rectification Buck circuit; the ninth switch tube (Q 9 ), the fifth diode (D 5 ), the fifth inductor (L 4 ) 5 ) and the second capacitor (C o ) to form a Boost circuit; one end of the upper tube of the four-way synchronous rectification Buck circuit is connected to the positive pole of the input DC power supply, and the other end is connected to the first inductance (L 1 ) and the second inductance (L 1 ) respectively. 2 ), the third inductor (L 3 ) and the fourth inductor (L 4 ) are connected in series; one end of the lower tube of the four-way synchronous rectification Buck circuit is connected to the first inductor (L 1 ), the second inductor (L 2 ), The series point between the third inductor (L 3 ), the fourth inductor (L 4 ) and the upper tube, and the other end is connected to the negative pole of the input DC power supply, which is ground; the first inductor (L 1 ) in the four-way synchronous rectification Buck circuit ), the second inductor (L 2 ), the third inductor (L 3 ), and the fourth inductor (L 4 ) have one end connected to the common point of the upper and lower tubes, and the other end connected to the positive pole of the output diode; four-way synchronous rectification The cathodes of the output diodes in the Buck circuit are connected together to one end of the switching tube (Q L ) of the low-voltage discharge circuit, and the low-voltage discharge The other end of the circuit switching tube (Q L ) is connected to the positive pole of the gap; the Boost circuit is connected in parallel with the four-way synchronous rectification Buck circuit, that is, one end of the fifth inductor (L 5 ) is connected to the positive pole of the input DC power supply, and the other end is connected to the fifth and second The anode of the pole tube (D 5 ); the cathode of the fifth diode (D 5 ) is connected to the high voltage breakdown circuit switching tube (Q H ); one end of the ninth switch tube (Q 9 ) is connected to the fifth inductor (L 5 ) The common point between it and the fifth diode (D 5 ), and the other end is connected to the negative pole of the input DC power supply, which is the ground; one end of the second capacitor (C o ) is connected to the fifth diode (D 5 ) and the The common point between the high-voltage breakdown circuit switching tubes (Q H ), and the other end is connected to the negative pole of the input DC power supply, which is the ground; the first capacitor (C in ) is connected in parallel with the DC input power supply; the feedback diode (D back ) The negative electrode is connected with the positive electrode of the DC power supply, and the positive electrode is connected with the negative electrode of the first output diode (D 1 ); the two ends of the gap are also connected in parallel with the deionization switch tube (Q off ); the other end of the gap is connected to the input Negative pole of DC power supply. 3.根据权利要求2所述的基于Boost和Buck并联的高低压复合型脉冲电源，其特征在于，所述第一开关管(Q1)、第二开关管(Q2)、第三开关管(Q3)、第四开关管(Q4)、第五开关管(Q5)、第六开关管(Q6)、第七开关管(Q7)、第八开关管(Q8)、第九开关管(Q9)、消电离开关管(Qoff)、低压放电电路切换管(QL)、高压击穿电路切换管(QH)采用金属-氧化物半导体场效应晶体管。3. The high and low voltage composite pulse power supply based on Boost and Buck in parallel according to claim 2, wherein the first switch tube (Q 1 ), the second switch tube (Q 2 ), the third switch tube (Q 3 ), the fourth switch tube (Q 4 ), the fifth switch tube (Q 5 ), the sixth switch tube (Q 6 ), the seventh switch tube (Q 7 ), the eighth switch tube (Q 8 ), The ninth switch tube (Q 9 ), the deionization switch tube (Q off ), the low-voltage discharge circuit switch tube (Q L ), and the high-voltage breakdown circuit switch tube (Q H ) use metal-oxide semiconductor field effect transistors. 4.根据权利要求2所述的基于Boost和Buck并联的高低压复合型脉冲电源，其特征在于，所述第一电感(L1)、第二电感(L2)、第三电感(L3)、第四电感(L4)、第五电感(L5)选择独立电感，磁芯选择由氧化铁混合物组成的烧结磁性金属氧化物，其材料为PC40。4. The high and low voltage composite pulse power supply based on Boost and Buck in parallel according to claim 2, wherein the first inductor (L 1 ), the second inductor (L 2 ), and the third inductor (L 3 ) ), the fourth inductor (L 4 ), and the fifth inductor (L 5 ) are selected as independent inductors, and the magnetic core is selected as a sintered magnetic metal oxide composed of a mixture of iron oxide, and its material is PC40. 5.根据权利要求2所述的基于Boost和Buck并联的高低压复合型脉冲电源，其特征在于，所述第一输出二极管(D1)、第二输出二极管(D2)、第三输出二极管(D3)、第四输出二极管(D4)、第五二极管(D5)和反馈二极管(Dback)采用肖特基二极管。5. The high and low voltage composite pulse power supply based on Boost and Buck in parallel according to claim 2, wherein the first output diode (D 1 ), the second output diode (D 2 ), the third output diode (D 3 ), the fourth output diode (D 4 ), the fifth diode (D 5 ) and the feedback diode (D back ) employ Schottky diodes. 6.根据权利要求1所述的基于Boost和Buck并联的高低压复合型脉冲电源，其特征在于，所述间隙电压检测电路选择电阻分压电路。6 . The high and low voltage composite pulse power supply based on the parallel connection of Boost and Buck according to claim 1 , wherein the gap voltage detection circuit selects a resistor divider circuit. 7 . 7.根据权利要求1所述的基于Boost和Buck并联的高低压复合型脉冲电源，其特征在于，所述间隙电流检测电路选择电流霍尔传感器。7 . The high and low voltage composite pulse power supply based on the parallel connection of Boost and Buck according to claim 1 , wherein the gap current detection circuit selects a current Hall sensor. 8 . 8.根据权利要求1所述的基于Boost和Buck并联的高低压复合型脉冲电源，其特征在于，所述FPGA控制器选用AX301系列开发板。8. The high and low voltage composite pulse power supply based on Boost and Buck in parallel according to claim 1, wherein the FPGA controller selects AX301 series development boards for use. 9.根据权利要求1所述的基于Boost和Buck并联的高低压复合型脉冲电源，其特征在于，所述驱动电路选用自带隔离的高低侧双路输出的驱动芯片。9 . The high and low voltage composite pulse power supply based on Boost and Buck in parallel according to claim 1 , wherein the drive circuit selects a drive chip with self-isolated high and low side dual outputs. 10 . 10.基于权利要求1-9任一项所述电源的加工控制方法，其特征在于，包括如下步骤：10. The processing control method based on the power supply of any one of claims 1-9, characterized in that, comprising the steps of: 步骤一：在击穿延时阶段，FPGA控制器控制低压放电电路切换管(QL)关断，高压击穿电路切换管(QH)导通，消电离开关管(Qoff)关断；第一开关管(Q1)、第二开关管(Q2)、第三开关管(Q3)、第四开关管(Q4)、第五开关管(Q5)、第六开关管(Q6)、第七开关管(Q7)、第八开关管(Q8)关断；此时由第九开关管(Q9)、第五二极管(D5)、第五电感(L5)和第二电容(Co)组成的Boost电路向间隙提供高压，FPGA控制器根据加工环境以及间隙采样电压与电压设定值(vopen)的误差信号输出PWM信号控制第九开关管(Q9)的占空比，从而调节施加到间隙两端的高压大小，形成稳定的放电通道；Step 1: in the breakdown delay stage, the FPGA controller controls the low-voltage discharge circuit switching tube (Q L ) to be turned off, the high-voltage breakdown circuit switching tube (Q H ) is turned on, and the deionization switch tube (Q off ) is turned off; The first switch tube (Q 1 ), the second switch tube (Q 2 ), the third switch tube (Q 3 ), the fourth switch tube (Q 4 ), the fifth switch tube (Q 5 ), the sixth switch tube ( Q 6 ), the seventh switch tube (Q 7 ), and the eighth switch tube (Q 8 ) are turned off; at this time, the ninth switch tube (Q 9 ), the fifth diode (D 5 ), the fifth inductor ( The Boost circuit composed of L 5 ) and the second capacitor (C o ) provides high voltage to the gap, and the FPGA controller outputs a PWM signal to control the ninth switch tube according to the processing environment and the error signal between the gap sampling voltage and the voltage set value (v open ) (Q 9 ) duty cycle, thereby adjusting the magnitude of the high voltage applied to both ends of the gap to form a stable discharge channel; 步骤二：当间隙击穿后，进入放电阶段，间隙电压从原来的开路电压(vopen)下降到维持电压(vdis)，FPGA控制器输出多路PWM信号控制低压放电切换管(QL)导通，高压击穿电路切换管(QH)关断，完成从高压击穿电路切换到低压放电电路；Step 2: When the gap breaks down, it enters the discharge stage, the gap voltage drops from the original open-circuit voltage (v open ) to the maintenance voltage (v dis ), and the FPGA controller outputs multiple PWM signals to control the low-voltage discharge switching tube (Q L ) On, the high-voltage breakdown circuit switching tube ( QH ) is turned off, completing the switch from the high-voltage breakdown circuit to the low-voltage discharge circuit; 步骤三：高压击穿电路与低压放电电路切换完成后，低压放电电路开始向间隙提供加工所需要的放电能量，FPGA控制器根据间隙采样电流(id)与电流参考值(iref)的误差信号输出多路PWM信号控制四路同步整流Buck电路交错工作，相邻两路之间的PWM信号相位差等于开关周期的四分之一，且单路同步整流Buck电路上下管之间的驱动信号留有一定的死区时间，此时进入持续放电加工阶段；Step 3: After the switching between the high-voltage breakdown circuit and the low-voltage discharge circuit is completed, the low-voltage discharge circuit begins to provide the discharge energy required for processing to the gap, and the FPGA controller samples the error between the current ( id) and the current reference value (i ref ) according to the gap Signal output The multi-channel PWM signal controls the interleaved operation of the four-channel synchronous rectification Buck circuit. The phase difference of the PWM signal between the adjacent two channels is equal to one quarter of the switching period, and the driving signal between the upper and lower tubes of the single-channel synchronous rectification Buck circuit is There is a certain dead time, and then it enters the continuous discharge machining stage; 步骤四：当放电持续时间(脉宽)达到设定值(ton)时，FPGA控制器输出多路PWM信号控制低压放电电路切换管(QL)关断，高压击穿电路切换管(QH)关断，消电离开关管(Qoff)关断，第一开关管(Q1)、第三开关管(Q3)、第五开关管(Q5)、第七开关管(Q7)关断，第二开关管(Q2)、第四开关管(Q4)、第六开关管(Q6)、第八开关管(Q8)导通，第九开关管(Q9)关断，第一电感(L1)、第二电感(L2)、第三电感(L3)、第四电感(L4)、第五电感(L5)中的能量通过反馈二极管(Dback)回馈给输入直流电源，此时进入放电拖尾阶段。Step 4: When the discharge duration (pulse width) reaches the set value (t on ), the FPGA controller outputs multiple PWM signals to control the low-voltage discharge circuit switching tube (Q L ) to turn off, and the high-voltage breakdown circuit switching tube (Q H ) is turned off, the deionization switch tube (Q off ) is turned off, the first switch tube (Q 1 ), the third switch tube (Q 3 ), the fifth switch tube (Q 5 ), and the seventh switch tube (Q 7 ) ) is turned off, the second switch tube (Q 2 ), the fourth switch tube (Q 4 ), the sixth switch tube (Q 6 ), and the eighth switch tube (Q 8 ) are turned on, and the ninth switch tube (Q 9 ) Turn off, the energy in the first inductor (L 1 ), the second inductor (L 2 ), the third inductor (L 3 ), the fourth inductor (L 4 ), and the fifth inductor (L 5 ) passes through the feedback diode (D back ) is fed back to the input DC power supply, and now it enters the discharge tail stage. 步骤五：间隙电流降到零之后，FPGA控制器输出多路PWM信号控制消电离开关管(Qoff)导通，其他的开关管均关断，使得间隙两端电压降为零，进入消电离阶段，为下一周期的放电做准备；Step 5: After the gap current drops to zero, the FPGA controller outputs multi-channel PWM signals to control the deionization switch (Q off ) to be turned on, and other switches are turned off, so that the voltage across the gap drops to zero and enters the deionization process. stage, to prepare for the discharge of the next cycle; 步骤六：重复上述五步骤，实现加工周期的循环。Step 6: Repeat the above five steps to realize the cycle of the processing cycle.
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